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March 2024

Newhaven receives pontoon upgrade

As part of the refurbishing of the operations and maintenance (O&M) base for the Rampion Offshore Wind Farm, Inland and Coastal Marina Systems (ICMS) has installed a floating concrete breakwater within the Port of Newhaven to provide safe berthing facilities for crew transfer vessels (CTVs).

Working with civil engineering firm Knights Brown, ICMS designed and installed a 90-linear-meter concrete breakwater with 1-meter freeboard, suitable for berthing CTV vessels up to 140-metric-ton displacement. The floating structure, with external pile guides, has a width of 4.5 meters, providing ample space for the associated electrical, water, lighting, and fuel services required.

“Working closely with the team at Knights Brown, we were able to install the new access system and pontoon without disruption of the 24/7 operations and maintenance activities of the wind farm,” said Jon Challis, ICMS sales manager.

“We also worked alongside sub-contractors for the pontoons’ services to ensure full compliance with health, safety and quality management procedures as we installed the new berthing facility, which will benefit vessel operators for years to come.”

Rampion was the first offshore wind farm off the south coast of England and is owned and operated by RWE Renewables. The O&M base is a permanent structure within the Port of Newhaven, comprising offices, warehousing, and berthing and quayside facilities for the wind-farm commissioning and maintenance vessels.

Manufactured in ICMS’ highly controlled pre-cast facilities in Banagher, Ireland, the concrete pontoon has a 200mm rubber D-fender and one-meter freeboard to match that of the vessels using it, creating a comfortable berthing facility for the CTVs serving the Rampion Offshore Wind Farm.

With a durable, textured decking designed for commercial use, the crews have continuous safe access to their vessels night and day, year round, whatever the weather.

“I can truly say it’s been an absolute pleasure working with Inland and Coastal’s project team from the start of the design stage to the delivery of the breakwater and the successful hand over to our client,” said Arron Dolan, contracts manager at Knights Brown. “We have found the project team to be user friendly and always on hand to support the team with any queries. We found their on-site team helpful and accommodating at all times. I would personally highly recommend them.”

More info www.inlandandcoastal.com

DNV opens training hub in Abu Dhabi

DNV, the independent assurance and risk management provider, has formally opened THInK, its new Training Hub for Industrial Knowledge, in Abu Dhabi, United Arab Emirates.

The dedicated training facility, the first of its kind in the region, will offer a range of comprehensive programs, underscoring DNV’s commitment to enhancing the abilities of those entering, and already in, multiple industry sectors. Ensuring that workers have the latest skills and knowledge is essential for businesses to create a competitive advantage in a rapidly evolving and challenging industry. 

THInK will offer a personal and customizable approach to development, offering in-person, virtual, and hybrid training sessions. DNV will also make use of virtual reality (VR) technology to safely replicate hands-on experiences in high-risk industries. 

The hub will allow access to a variety of internationally accredited courses on safety, lifting, Mobile Elevating Work Platforms (MEWP), earth-moving machinery, and scaffolding, among others. Fully customized classes can be developed and adapted to meet the specific needs of clients or industries.

Each course is designed to cater to different areas of expertise and will be taught by trainers with years of field experience and are still involved in real-life projects on a daily basis.   

“THInK will become a repository of industry knowledge that will truly allow people to realize their full potential and accelerate their development,” said Mohamed Houari, DNV Inspection’s global managing director. “This will be done through a combination of traditional training methods as well as innovative methodologies such as virtual reality and artificial intelligence. THInK is the latest testimony of our investment in UAE and our commitment to In-Country-Value.”

More info www.dnv.com

METIS, ESVAGT join forces to bring analytics offshore

METIS Cyberspace Technology is expanding its portfolio of data acquisition, real-time performance monitoring, and intelligent analytics solutions to include the needs of service operation vessels (SOV). The move follows a collaborative project covering fleet performance optimization with leading offshore service provider for wind/oil & gas industries, ESVAGT.

METIS has developed a way of visualizing SOV operations which correlates the full range of vessel activities to fuel efficiency and emissions in the context of a five-day forecast for weather conditions. (Courtesy: METIS)

The SOV fulfils multiple roles — as transport ship, accommodation vessel, warehouse and workshop — presenting a challenge when it comes to assessing overall efficiency. Following an ESVAGT initiative, METIS has developed a portfolio of applications to enhance SOV operations. Leveraging ESVAGT’s operational expertise and data, METIS utilized its high-frequency data acquisition and advanced performance evaluation analytics to provide transparency in the performance of SOVs.

“The result is an exciting example of how advanced analytics deliver a competitive edge, in this case creating the opportunity for SOVs to offer added value services to end clients,” says Panos Theodossopoulos, chief executive officer, METIS Cyberspace Technology. “I would like to thank ESVAGT for its cooperation in taking our product and service development in a new direction.”

METIS has developed a way of visualizing SOV operations, which correlates the full range of vessel activities to fuel efficiency and emissions in the context of a five-day forecast for weather conditions, according to Theodossopoulos.

Features include a new depiction of total fuel oil consumption by activity across multiple scenarios, including transit, personnel transfer, time-in-port, etc., which takes account of different weather conditions. The enhanced software functionality also introduces a heightened level of transparency to dynamic positioning (DP) operations taking into consideration that DP systems play a critical role in maintaining positions and ensuring the safe transfer of technicians to offshore installations using “walk-to-work” gangways.

DP systems use a vessel’s propellers and thrusters to maintain a position and heading, taking account of external conditions. The new METIS DP Motion Analysis App analyses the performance of the vessel’s power system during DP to deliver a visualization of aggregated SOV performance based on fuel and energy efficiency, environmental conditions and motion dynamics.

Also new is METIS functionality harvesting weather forecast and vessel performance data with the transparency to help site managers and vessel operators work together to schedule maintenance most effectively. The “Smart Scheduler” refines existing METIS voyage routing optimization to take account of planning for wind farm operations, including safety requirements.

“The new functionality supports better voyage planning and performance at sea during the key tasks which define SOV utilization,” said Kristian Ole Jakobsen, DCEO, ESVAGT. “In doing so, AI-based analytics is helping vessel operators to contribute to a more efficient and sustainable offshore wind industry.”

More info www.metis.tech

Emerson’s PC built to connect industrial floor to cloud

Emerson recently announced the new PACSystems™ IPC 2010 Compact Industrial PC (IPC), a rugged industrial computer designed to handle a wide range of machine and discrete part manufacturing automation applications. The new solution is designed to serve manufacturing sites and OEM machine builders that need a ruggedized, compact, durable IPC to cost-effectively support their Industrial Internet of Things (IIoT) and other digital transformation initiatives.

Emerson’s PACSystems™ IPC 2010 Compact Industrial PC is designed to serve manufacturing sites and OEM machine builders who need a ruggedized, compact, durable IPC. (Courtesy: Emerson)

The IPC 2010 addresses this by pre-loading the PACEdge™ industrial edge platform and elements of Movicon.NExT™ SCADA software, helping users run applications quickly using browser-based configuration. Provisions are included for keeping the software platform current and passively maintained, minimizing user effort, while maximizing reliability.

Running an industrial version of Linux and including serial and Ethernet connectivity, the IPC 2010 can be used as a communications gateway in a variety of topologies and simultaneously or separately as an edge computing device.

Users can implement the IPC 2010 as a flexible protocol converter — and for many other computing functions — in many IIoT, edge, OT/IT convergence, HMI visualization, SCADA connectivity, and digital transformation roles.

Both the hardware and software are designed to be adaptable, universal, and scalable, providing a standardized and unified user experience that is easy-to-use, powerful, and supported by Emerson’s lifecycle services.

The compact form factor IPC 2010 features the widest operating temperature range of any passively cooled IPC, with a low power consumption of just 4 watts and tough packaging, so it can be installed virtually anywhere.

The IPC 2010 offers an advantageous price/performance ratio, with no ongoing annual licensing costs, or charges for general and cybersecurity updates. Additional features, such as Movicon Connext© or WebHMI, can be activated or added at any time.

“Many customers undergoing a digital transformation want to start small and earn trust as they seek out value from edge-enabled applications,” said William Paczkowski, product manager for the IPC 2010 for Emerson’s discrete automation business. “The IPC 2010 is specifically designed as a pre-packaged and economical solution so they can get running quickly and cost effectively.”

Emerson is already building the IPC 2010 into a range of larger offerings for leak detection, compressed air monitoring, batching systems, cloud enablement services, and other packaged solutions.

This flexible industrial technology will enable customers of all types to benefit from their advanced capabilities.

More info www.emerson.com

Siemens certifies Pfisterer’s Connex system

The Connex pluggable connection system from Pfisterer has been certified by Siemens Energy for use in 420 kV Clean Air switchgears. Clean Air is an environmentally friendly, non-polluting insulating medium as an alternative to the well-known insulating gas sulphur hexafluoride (SF6). Clean Air consists of natural components of ambient air, such as oxygen and nitrogen. The use of Clean Air is intended to help minimize the environmental effects of electrical switchgears.

Pfisterer’s Connex product family is the first pluggable connection technology for switchgear to be certified by Siemens Energy for 420 kV Clean Air applications. The socket forming the interface with the switchgear passed the dielectric type test with Clean Air according to IEC 62271- 203. The design of the socket was tested under increased pressure conditions, among other things.

Pfisterer is the first manufacturer to be certified for Clean Air switchgears. (Courtesy: Pfisterer)

“If electric power is generated in an environmentally friendly way, transmission and distribution must follow suit,” said Alejandro Escobin, head of product management HV cable accessories at Pfisterer. “Because our technology is used at the interfaces, it plays an important part in this. The successful testing confirms its reliability for Clean Air, which is an important step toward climate-friendly energy transmission.” “The pluggability of the Connex system allows it to be installed quickly and easily, with a minimal space requirement and maximum flexibility,” said key account manager Norbert Fink. “We are delighted that this technology will in future be contributing even more to improving sustainability.”

More info www.pfisterer.com

Weidmuller introduces smallest crimping tool

Weidmuller USA, a provider of smart industrial connectivity and automation products and solutions, has developed and launched the PZ 2.5 S, the smallest professional crimping tool on the market for wire end ferrules.

In control cabinet construction, cables of the most diverse cross-sections are fitted with wire end ferrules. On average, 90 percent of these connections are in a cross-section range of AWG 14 (2.5 square millimeters) and smaller. A focus on this cross-section range makes the PZ 2.5 compact and ergonomic – the small handle width and the opening angle, as well as the weight, make the tool easy to use without incurring fatigue in the hand, wrist, or arm.

Weidmuller USA’s PZ 2.5 S is the smallest professional crimping tool on the market for wire end ferrules. (Courtesy: Weidmuller USA)

The PZ 2.5 tool features a length of 160mm with a small grip width so it can easily fit in the palm of the hand. Weighing about 10 ounces, this compact tool is light to carry around for ergonomic advantage.

The trapezoidal crimp in the cross-section range of AWG 26 to AWG 14 (0.14-2.5 square millimeters) complies with all current standards. The practical universal die prevents incorrect insertion and ensures error-free work. The focus on small cross-sections also reduces wear, leading to a doubling of the service life of the PZ 2.5.

“By focusing on small cross-sections, it was possible to keep the size, weight, opening width, and actuating force of the PZ 2.5 small, without compromising on crimp quality,” said Niklas Bode, business development manager for workplace solutions in Weidmuller USA’s Cabinet Products Division.

More info www.weidmuller.com

Ocean Winds, Zelim work to enhance offshore wind safety

Zelim, a U.K.-based startup developing search and rescue solutions, is joining forces with Ocean Winds, an international company dedicated to offshore wind energy and 50-50 joint venture between EDP Renewables and ENGIE, in a pilot project to test AI-enabled person detection software for floating offshore wind farms. The objective is to test and prove Zelim’s ZOE technology, AI-enabled software dedicated to person overboard detection and capable of finding and tracking people, vessels, and other objects in real time and in harsh maritime conditions.

During the collaboration, Zelim will offer continuous monitoring of ZOE’s live feed from cameras installed on two turbine foundations on Ocean Winds’ WindFloat Atlantic project. The project will serve to train and improve the ZOE detection models whilst proving its capability.

Zelim has been developing its AI-enabled person detection software for floating offshore wind farms for the last three years. (Courtesy: Zelim)

ZOE will be detecting people and objects in the waters surrounding the turbines, providing direct alerts to the operation and maintenance control center in the case of a person falling overboard or an external vessel approaching the windfarm. By proving this capability, ZOE will support the site’s operation and effectiveness by providing an additional layer of health and safety support.

“Finding someone in distress at sea is often a game of chance, especially when you factor in waves, sea spray, darkness, and how quickly people can drift in the current,” said Doug Lothian, Zelim chief technology officer. “Couple that with the limitations of a human searcher’s eyesight and concentration. We have been developing ZOE over the last three years to increase certainty in search, even in challenging conditions. We see ZOE providing a safety net around offshore assets, where if somebody ends up in the water, they will be detected and an immediate alert sent, thereby enabling a fast and efficient rescue. We are thrilled to be working with the team at Ocean Winds to create a new benchmark in safety for offshore workers.”

“As a pure offshore wind developer and operator of over 1.5 GW in the world, a key focus at Ocean Winds is the increase of the safety and health of our workers and communities, which always come first,” said Elena Caja, HSSEQ director. “We are very excited for the implementation of this project and are looking forward to the results, and potential deployment throughout our projects already in operation or under construction.”

More info www.zelim.co/find | www.oceanwinds.com

DNV revises marine operations standard

DNV, the independent energy expert and assurance provider, has published a substantial revision to DNV-ST-N001, for the design and planning of marine operations for the transport, installation, and removal of offshore wind farms, subsea cables, and oil and gas assets.

The major changes reflect the changing nature of the offshore industry in line with its support of the energy transition, ensuring that the standard remains relevant and supports the development of cost-effective marine operations during a fast-evolving energy transition. DNV estimates that offshore wind will rise globally from 8 percent of total wind production in 2020 to 34 percent in 2050, totaling almost 2,000 GW.

“The latest revision of DNV-ST-N001 further reinforces its position as the de-facto standard used to safely undertake marine operations all over the world,” said Lucy Craig, DNV’s director of growth, innovation and digitalization, energy systems. (Courtesy: DNV)

Through continuous engagement with industry, DNV-ST-N001 has been regularly updated and enhanced since it was created in 2016. This revision follows an external hearing exercise, during which more than 400 comments from the industry were received, of which more than 350 were technical in nature. The standard first came about after DNV and Noble Denton legacy standards from the 1970s and ’80s were combined into one substantial and comprehensive document.

The standard can be applied to all marine operations and all key engineering requirements relevant to load-out, construction afloat, voyages, and installation, as well as the loads that should be addressed in the design of these marine operations. It also lays out the requirements from the perspective of the marine warranty surveyor, who reviews the marine operations.

“Following a high level of engagement from the industry, the latest revision of DNV-ST-N001 further reinforces its position as the de-facto standard used to safely undertake marine operations all over the world providing the needed assurance in the implementation of the energy transition,” said Lucy Craig, DNV’s director of growth, innovation and digitalization, energy systems. “Since the standard was first established, it has been vital that it has remained at the forefront of changes to the industry, and these updates will ensure that our customers continue to receive the highest possible standard of assurance.”

Industry engagement drove DNV to update a body of work that spans almost 800 pages, with collaboration spanning across the organization’s global network of marine operations and marine warranty survey experts, working in DNV’s Noble Denton marine services area.

“It was particularly encouraging to note the number of industry comments stemming from developers and contractors engaged in offshore wind-farm construction activities, which demonstrates the importance of the standard to the industry and also influenced updates to numerous areas of the standard,” said Ankor Raithatha, DNV’s global service area leader for Noble Denton. 

More info www.dnv.com

BOEM designates two wind-energy areas in Oregon

In support of the Biden-Harris administration’s goals for deploying 30 GW of offshore wind energy capacity by 2030 and 15 GW of floating offshore wind energy capacity by 2035, the Bureau of Ocean Energy Management has announced the designation of two final Wind Energy Areas (WEAs) offshore Oregon. The WEAs were developed following extensive engagement and feedback from the state, Tribes, local residents, ocean users, federal government partners, and other members of the public. The final WEAs are based on reducing potential conflicts of ocean users, particularly on commercial fishing.

The two WEAs total about 195,012 acres, and they avoid 98 percent of the areas recommended for exclusion due to their importance as commercial fishing grounds. The Coos Bay WEA is 61,204 acres and is 32 miles from shore. The Brookings WEA is 133,808 acres and is about 18 miles from shore.

The two Oregon WEAs total about 195,012 acres. (Courtesy: BOEM)

“BOEM values its close coordination with the State of Oregon as we continue to work together to maintain a robust and transparent offshore wind planning process,” said BOEM Director Elizabeth Klein. “We will continue to work closely with Tribal governments, federal and state government agencies, ocean users, coastal communities and all interested stakeholders as we move forward with our environmental review.”

BOEM’s Federal Register notice will initiate a 30-day public comment period. Another public comment period would occur if BOEM decides to move forward with a lease sale in either of the WEAs.

In addition to engaging with the State, Tribes, coastal communities and ocean users, BOEM partnered with the National Oceanic and Atmospheric Administration’s National Centers for Coastal Ocean Science (NCCOS) to assess opportunities for wind-energy development and reduce or avoid impacts on other important ocean uses in Oregon. The agencies developed a comprehensive, ecosystem-based ocean planning model that leverages the best available data on natural resources, ocean industries such as fisheries and energy production, and areas of national security activities to identify areas with high wind-energy resource potential and fewer potential impacts to other ocean users and sensitive environmental resources. This approach provided valuable insights about the seascape and its uses and facilitated greater transparency and positive coordination with government partners and ocean stakeholders through direct engagement and incorporation of their feedback into the NCCOS model.

Since the start of the Biden administration, the Department of the Interior has approved the nation’s first six commercial-scale offshore wind energy projects. BOEM has held four offshore wind lease auctions, which have brought in almost $5.5 billion in high bids, including a sale offshore New York and New Jersey and the first sales offshore the Pacific and Gulf of Mexico coasts. BOEM is exploring opportunities for offshore wind energy development in the U.S., including in the Gulf of Maine and the U.S. Central Atlantic coast. The Department also continues to take steps to evolve its approach to offshore wind to drive towards union-built projects and a domestic-based supply chain.

More info www.boem.gov/newsroom

BOEM approves construction plan for offshore project

In support of the Biden-Harris administration’s goal of deploying 30 GW of offshore wind energy capacity by 2030, the Bureau of Ocean Energy Management (BOEM) recently announced its approval of Empire Wind’s Construction and Operations Plan (COP), which authorizes construction and operation of the wind-energy project offshore. This is the project’s final approval from BOEM, following the agency’s Record of Decision approving the project in November 2023. 

New York proposed lease area. (Courtesy: BOEM)

“We are proud to announce BOEM’s final approval of the Empire Wind offshore wind project,” said Director Elizabeth Klein. “This project represents a major milestone in our efforts to expand clean-energy production and combat climate change. The Biden-Harris administration is committed to advancing offshore wind projects like Empire Wind to create jobs, drive economic growth, and cut harmful climate pollution.”

The approved plan includes construction and operation of two offshore wind facilities, known as Empire Wind 1 and Empire Wind 2. The lease area is about 12 nautical miles south of Long Island, New York, and about 16.9 nautical miles east of Long Branch, New Jersey. Together these projects would have a total capacity of 2,076 MW of clean, renewable energy that BOEM estimates could power more than 700,000 homes each year. 

On Nov. 21, 2023, the Department of the Interior announced its approval of the Empire Wind offshore wind project, which is the sixth commercial-scale offshore wind project approved by the Biden-Harris administration. It is expected to generate significant economic benefits for New York and the surrounding region, including supporting more than 830 jobs each year during the construction phase and about 300 jobs annually during the operations phase.

Since the start of the Biden-Harris administration, the Department of the Interior has approved the nation’s first six commercial-scale offshore wind-energy projects. BOEM has held four offshore wind lease auctions, which have brought in almost $5.5 billion in high bids, including a record-breaking sale offshore New York and New Jersey and the first-ever sales offshore the Pacific and Gulf of Mexico coasts. BOEM has also advanced the process to explore additional opportunities for offshore wind-energy development in the Gulf of Maine, Gulf of Mexico, offshore Oregon, and the Central Atlantic coast. The Department has taken steps to evolve its approach to offshore wind to drive toward union-built projects and a domestic-based supply chain.

More info www.boem.gov/renewable-energy/state-activities/empire-wind

Clearway partially repowers 55-MW wind farm in Texas

Clearway Energy Group recently announced it completed a partial repower of the Ocotillo Windpower wind farm (“Ocotillo”) in Howard County, Texas.

The 55-MW wind farm will generate enough electricity each year to power more than 19,000 homes for another decade. In addition, the wind-project repower will provide an additional $2 million in property taxes to Howard County and extends landowner lease payments over the same period.

Ocotillo Windpower wind farm will generate enough electricity each year to power more than 19,000 homes for another decade. (Courtesy: Clearway Energy Group)

“The industry has reached a point of maturity where some of the windiest places in the country already provide clean, reliable energy for Americans,” said John Martinez, SVP of Operations at Clearway. “The innovation of repowerings like this one proves that renewable energy projects don’t need to have a shelf life. By upgrading components with the latest state-of-the-art technology on the market, we’re able to keep wind farms generating power for decades longer than anyone could have imagined.” 

The repower replaced major components across the site’s 26 turbines, including blades, generators, gearboxes, and drive-train parts for some turbines, and upgraded operating systems for all turbines.

The wind farm began its original commercial operations in 2008. Clearway’s public affiliate, Clearway Energy, Inc., acquired the project in 2020 to extend the life of the project, leveraging prior repowering experience.   

A portion of the renewable attributes from Ocotillo were purchased on behalf of eight corporate buyers through Ever.green, a marketplace for high-impact Renewable Energy Certificates (“REC”). The RECs will go toward supporting Ever.green’s corporate customers in achieving their respective decarbonization goals through REC purchases.

This is Clearway’s fourth wind farm repower in Texas and fifth across its portfolio. Research firm Wood Mackenzie estimates that repowerings will be performed on 20 percent of the country’s existing wind fleet by 2028.

Clearway Energy Group is leading the transition to a world powered by clean energy. Along with its public affiliate Clearway Energy, Inc., it owns and operates more than 8 GW of renewable and conventional energy assets across the country. As it develops a nationwide pipeline of new renewable energy projects for the future, Clearway’s 5.6 GW of wind, solar, and energy storage assets offset the equivalent of more than 10.5 million metric tons of carbon emissions for its customers. Clearway Energy Group is headquartered in San Francisco with offices in Carlsbad, California; Scottsdale, Arizona; Houston, Texas; and Princeton, New Jersey.

More info clearwayenergygroup.com

American Wire names renewable energy sales VP

American Wire Group (AWG) has appointed Scott Taylor as vice president of regional sales for its renewable energy division. Taylor will be responsible for serving AWG’s customers engaged with new construction, repower, operations, and maintenance within the wind, solar, and battery energy storage industries. He will report to Norman Russell, chief revenue officer at AWG.

Scott Taylor is AWG’s new vice president of regional sales for its renewable energy division. (Courtesy: American Wire Group)

“We are excited to welcome Scott to our growing renewables team of seasoned professionals,” Russell said. “His diverse experience in the industry will prove to be a valuable asset for our company, contributing insights and driving business success in every collaborative endeavor.”

Scott is based in Houston, Texas, and brings more than 20 years of experience in electrical engineering, regional sales management, and business development within the wire and cable manufacturing and distribution sectors. He holds an electrical engineering degree from the University of Tennessee.

American Wire Group (AWG) is a leading material supplier of wire and cable, hardware, equipment, and accessory solutions for the utility and renewable-energy market.

More info www.buyawg.com

New Jersey awards offshore wind contracts

New Jersey has awarded offshore wind contracts to the 1.3-GW Attentive Energy Two and the 2.4-GW Leading Light Wind projects in an accelerated auction round.

Attentive Energy Two is a joint venture between TotalEnergies and Corio Generation. Leading Light, which is expected to start producing power in 2031, is a partnership between U.S. energy firms Invenergy and energyRe.

The New Jersey Board of Public Utilities said two wind projects would bring about $6.8 billion in economic benefits to the state. (Courtesy: Attentive Energy)

“Today’s Third Solicitation awards are undeniable proof that the future of offshore wind in New Jersey is as strong as ever,” said Gov. Phil Murphy.

The New Jersey Board of Public Utilities said the two projects would bring about $6.8 billion in economic benefits to the state and provide enough clean energy to power about 1.8 million homes.

The projects will support the construction of a turbine tower factory at the New Jersey Wind Port and invest in the expansion of the EEW monopile facility at the Port of Paulsboro, the board said in a statement.

The awards came after a tumultuous year that saw the cancellation of several offshore wind projects in the northeast U.S. due to higher costs. In October, Orsted canceled Ocean Wind 1 and 2 off the coast of New Jersey, citing soaring inflation, rising interest rates, and delays in securing ships needed to build the projects.

New Jersey, which plans to build 11 GW of offshore wind energy by 2040, is slated to launch another offshore wind solicitation this year and expects to award those new contracts in early 2025.

More info www.reutersevents.com/renewables/wind

Conversation with Jonas Røstad and Lars Ivar Leivestad

What about Miros’ technology makes it important to the offshore wind industry?

There is a raft of benefits to having real-time wave radar measurements, and it is fast becoming a must for all offshore operations, including the wind sector. Wave radars provide accurate measurements and detailed information about the sea state conditions at an offshore wind farm, becoming an invaluable addition and supplement to the weather forecasts that have been in use for years.

Offshore wind projects are highly dependent on weather conditions across all phases, from installation right through to operations and maintenance. Real-time wave monitoring provides critical data for decision-making related to maintenance schedules, personnel transfers, and overall project planning. Accurate wave monitoring also enables offshore wind operators to optimize their O&M activities by giving them a picture of real-time sea conditions, meaning decisions can be made to enhance operational efficiency and reduce downtime. Up-to-the-minute information can act as an early warning system, too, allowing for timely responses to adverse sea conditions. This is crucial for the safety of personnel and the protection of equipment.

There is also a cost incentive for offshore wind developers to invest in real-time wave monitoring systems early. Unplanned downtime due to adverse weather conditions can be costly, but with the right sea state, data operators can mitigate risks and be proactive to reduce the amount of time a wind turbine is out of operation. Turbines are exposed to varying sea conditions and thorough information can help to assess the impact of waves on their structural integrity, meaning measures can be put in place to prevent damage. This leads to better asset management strategies and allows for the prediction of potential wear and tear on equipment, facilitating more responsive maintenance operations and extending the lifespan of wind farms.

Continuous real-time wave monitoring generates valuable data for offshore wind operations, research and analysis. In addition to the great value real-time wave data brings to the offshore wind operations, it also contributes to a better understanding of the offshore environment, improving future project planning and design. Moreover, regulatory authorities often require adherence to safety standards, including monitoring sea conditions.

Miros’ wave radar technology is dry-mounted, avoiding the harsh conditions typically faced by sensors that are submerged in water, leading to less or no maintenance. Miros’ sensors are also of high quality and the result of 40 years of technological development. Developed for harsh weather conditions in the North Sea, Miros’ technology is suitable for use anywhere.

IoT-enabled sensors also means that data can be sent to the cloud, and the system can communicate and interact over the internet, allowing it to be remotely monitored and controlled. All interested stakeholders can access the data and use it to support decisions. All this hardware is backed up by Microsoft Azure and its world-class cybersecurity.

Real-time wave data is important both in the installation phase and the operational phase. As soon as the first foundation is in the water, a Miros wave radar can be installed, providing real-time wave data to support operational decisions for the installation of the remaining OW foundations and WTGs.

What are the risks for offshore developers of not having accurate, real-time sea state monitoring?

First of all, there are safety concerns to consider. Accurate sea-state monitoring is crucial for the protection of offshore operations as unpredictable or severe sea conditions can pose a threat to personnel, equipment, and structures. Without real-time monitoring, there’s also a risk of exposing turbine structures to conditions they are not designed for, potentially leading to structural damage or failure.

Weather and sea state can change quickly and can disrupt offshore operations. For example, high waves or rough seas may hinder the transfer of personnel, equipment, or supplies, affecting project timelines and productivity. Wind turbines and other offshore equipment, such as cranes or gangways used for walk-to-work operations, may also be susceptible to damage in adverse sea conditions. Real-time monitoring allows for timely adjustments or shutdowns to prevent equipment damage.

More broadly, without real-time sea-state information vessel navigation becomes more challenging, increasing the risk of collisions, groundings, or other accidents. Moreover, if operators base their operational windows on weather forecast and not on accurate real-time measurements, operations can be stopped earlier or later than necessary. If stopped earlier, it can result in project delays and affect the overall budget.

If they are stopped too late, you risk exposing personnel and equipment to unnecessary threats. Also, when starting operations after weather down time, real-time measurements will be an objective decision for when operations can start up again.   

What is the “as-a-Service” business model, and what are the benefits to offshore wind operators?

By subscribing to Miros’ technology, rather than buying it outright, clients receive premium support and guaranteed uptime inclusive, increasing the operational output of wind turbines. Under as-a-Service, an advantageous sensor warranty, and the latest Microsoft Azure cybersecurity are included as a standard. If any matters or questions arise, Miros experts are ready to address them.

Should any barriers occur, we usually solve them quickest remotely; in the rare case that is not possible, we’ll send an expert to do the job in person. However, if a client decides to solely buy hardware from us or any other competing brands without a cloud subscription, they will also need to manage any hiccups themselves or send the equipment for repair. That takes more time and might have a significant impact on the operations and safety of their asset. Also, if we own and monitor the equipment, we make sure that it is future-proof. We will regularly upgrade the software remotely, so it always holds the highest standards. That way, it will not become outdated as technology progresses, and performance interruptions will be avoided.

Then there are co-creation and the ability for multiple users to benefit from the same interface. Measurements from the wave radars are sent right to the cloud, meaning they can be viewed wherever and whenever on any device, and shared with other companies that are working on the wind farm.

Having this first-hand access to both the technology and the data, we facilitate a close and powerful cooperation with our customers that allows us to continuously improve the applications as well as immediately take necessary measures should any data irregularities be spotted.

What trends do you anticipate being important for wave measurements in 2024?

Wave Prediction is high on the agenda for many offshore vessel owners and operators. Knowing the waves and the corresponding vessel movement up to two minutes ahead of time will help to ensure safer operations and optimal timing for operations such as crew transfers, cable laying, anchor handling, etc. Miros’ wave prediction is developed and tested in cooperation with key customers and the initial results are very promising.

The use of multiple wave sensors at offshore wind farms for optimizing O&M operations and enhancing safety will also continue to increase. Many of the wind farms currently going into the operational phase, as well as those that have been spinning for many years, will start to look at how they can optimize their maintenance scheduling and operations. Miros’ WaveFusion is already well received by the offshore wind market and more and more companies see the benefits of this sensor in combination with the as-a-Service business model.

Miros ensures high quality and accurate wave data is sent to the cloud and is accessible by all the customer’s stakeholders, anywhere and on any device, further assisting the planning and delivery of O&M operations.

Full scale floating offshore wind farms will soon become a reality with multiple projects in the pipelines. These wind farms will, in most cases, be located further offshore, where there is more variability in weather, rougher conditions, and more storms. Operators will need a better understanding of the changing weather conditions, which means even more accurate data and more measurement points will be needed at wind farms.

There will also be a need for wave monitoring to ensure the safety of the assets in high seas. The automatic shutdown of the turbines solely based on wind speed is no longer sufficient, platform movements will also be important and must be taken into consideration when asset safeguarding systems are developed. 

How does Miros collaborate with its customers to provide its solutions?

Miros consistently works with its customers to address their challenges. We engage in close partnerships with numerous clients to ensure that we create solutions tailored to their specific needs, rather than presuming what they might require. This can involve modifying existing products and adapting solutions for new applications, continually expanding our product portfolio, and developing innovative solutions. Our goal is to support our customers in operating safely and efficiently at sea.

What technologies are Miros developing to further support operators’ understanding of the offshore environment?

Wave prediction is one of Miros’ latest developments, and it involves forecasting the behavior of ocean waves over a specific period. Utilizing accurate wave radar data, this process provides valuable information for maritime activities and offshore operations, aiding in decision-making for safety and efficiency at sea.

Miros Heading Advisor is a navigation tool designed to provide guidance on the optimal heading or direction for vessels. It assists marine operators in making informed decisions to navigate efficiently, avoid obstacles, and reach their destinations safely. This technology incorporates Miros’ real-time wave data, weather conditions, and navigational parameters to offer accurate heading recommendations for improved maritime operations.

Recently launched, Miros Forecast is an indispensable application where the ocean condition forecast vs. measured real-time conditions is visualized in an easy and intuitive dashboard in Miros Cloud. The application helps to elevate maritime safety and operational efficiency due to the integration of forecasts with real-time measured ocean data. In the ever-evolving landscape of maritime and offshore operations, staying vigilant and ahead of environmental conditions is paramount for ensuring safety, efficiency, and cost-effectiveness.

With Forecast, you get forecasted ocean-state data together with real-time measured data integrated into the easy and intuitive Miros Cloud dashboard.

Marine Operations teams can make data-led decisions by leveraging both forecast and real-time data in one simple dashboard.

Enhanced by visual alarms, operations teams can stay up-to-date when specific wave conditions surpass predefined limits keeping the operations safe and efficient. Real-time measurements combined with forecast data empower site managers to optimize the site efficiently. This optimization extends to various offshore activities on vessels, platforms, wind-farm ports, and coastlines, ultimately enhancing the ability to meet the project targets and within the regulatory safety policies.

We are also working to assist control room operators in the continuous assessment of both real-time and forecasted wave and weather data, enabling them to dynamically adjust their strategies.

Miros Forecast is also beneficial for diving and ROV technicians. In the challenging conditions of high seas with substantial waves, potential risks to ROVs are significant, particularly during deployment, maneuvering, or retrieval. Having precise information about both current and forecasted sea states empowers technicians to make well-informed decisions. 

MORE INFO  www.miros-group.com

Reimagining Ports and Infrastructure

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With all the moving parts — including policy, infrastructure, supply chains, even the very turbines themselves — being juggled during the creation of a wind farm, it becomes vital that someone must ensure all those constantly changing assets are managed properly and efficiently.

Managing these projects to completion can take years, and the experts behind Gateway Zero have made it their duty to assist these monumental projects in reaching their directive — to produce clean, renewable energy.

“We are really focused in developing, investing, and unlocking the port infrastructure required for the energy transition more holistically,” said João Metelo, founder and CEO of Gateway Zero. “Wind energy — both onshore and offshore — plays quite a large role in that.”

Gateway Zero is focused on developing, investing, and unlocking the port infrastructure required for the energy transition. (Courtesy: Gateway Zero)

Managing the Supply Chain

Part of that surrounds supply chain development, which entails investing in new elements of demand that will exist for the wind-energy port infrastructure. This could involve storing, importing, and exporting components for onshore wind, as well as supply chain development for the construction, operation, and maintenance of offshore wind, according to Metelo.

“Wind energy — given how large the components and the infrastructure required — does indeed take a major chunk of those needs,” he said.

All that involves the supply side, but there is also much work to be done with the demand side as well, according to Metelo. And this involves new markets that wind energy will serve.

“Historically they’ve been onshore power demand, but where we are going to go next is going to be creating molecules, liquids, and H2 in all its derivatives,” he said. “It will be new parts of the transportation, whether that’s air, whether that’s maritime, whether that’s on the ground with heavy duty, that’s still a major part to be developed. All those parts really link back to the major transportation areas, and certainly port infrastructure is at the nexus of all those. That’s a little bit of how I see wind very much in the middle of what we intend to invest in.”

Gateway Zero will be a developer and investor in this asset class, according to Metelo.

“We will be working with port operators, port landlords, and energy developers to really focus on developing this infrastructure with all that is required for a future energy transition,” he said. “That can be anywhere from developing a port for onshore wind import and export to offshore wind supply construction and operation and maintenance. But that can also be full decarbonization of the infrastructure associated with ports and serving with new clean-energy sources and liquids, things like maritime fuels and transporting those new clean fuels across the world. We really think about these asset classes holistically and operating as a partner and developer to existing operators and investors and to really develop business plans that can be financed and where we can add in private capital to develop the asset class even further.”

Wind energy — given how large the components and the infrastructure required — needs a reliable and robust infrastructure. (Courtesy: Gateway Zero)

Developing a Plan

To get to that point first involves a lot of meetings, according to Metelo.

“It involves really sitting down, in many cases, with the local cities, the local port owners and operators, and really identifying what the gaps are of each asset, and they can vary quite a bit,” he said. “Some assets are largely dedicated to offshore renewables. Some assets are completely focused just on maritime transport and re-identifying what the energy transition needs are of these asset owners. They come in and develop business plans together with them that can be financeable and where we can crowd in private capital to invest in those. It’s also working with existing and future tenants of those assets, because obviously tenants are a very important part of what a port does — both onshore tenants and offshore users — and really sitting down and trying to understand their needs and prepare the infrastructure for the future needs of those tenants.”

This will involve a team from Gateway Zero bringing together competencies from renewable energy, including ports and engineering challenges to try and address the needs of not only existing and future tenants and users, but also existing port asset owners in order to develop financeable business plans, according to Metelo.

“They can be quite different depending on what specific projects we’ll need to develop in each asset and in each location,” he said. “Because the needs and the demand will be looking for different things in each asset.”

The Goal: Energy Transition

All those come together for the benefit of energy transition, and that is the essence of what Gateway Zero does, according to Metelo.

“That means anything related to wind energy, clean fuels, hydrogen, clean maritime fuels, and even decarbonization of the activities at those assets themselves,” he said. “These are large assets, and you need major decarbonization happening, whether that’s power shoring for vessels or EV charging for trucks — really decarbonizing large areas that often times are the large high pollution areas. That will play a role in development. It really is an opportunity to build new business plans around those infrastructures that will require major transformation.”

That means Gateway Zero sees itself as an investor that is working to unlock the next 20 or 30 years of large volume deployment that will be required, according to Metelo.

Gateway Zero will work with port operators, port landlords, and energy developers to focus on developing the necessary infrastructure for wind. (Courtesy: Gateway Zero)

“The last two or three decades of growth in renewables dealt with existing onshore demand,” he said. “Now, we’re moving to a place where there are different sides of demand; there are different places of demand. In many parts of the world, there are different places where wind is being produced, namely offshore.”

And with that offshore development, Gateway Zero will be involved in developing the coastal infrastructure assets needed to connect the dots, according to Metelo. That could be anything from accelerating deployment on the supply side, allowing import and export, or allowing offshore renewables to come to shore and be deployed.

“But that can also be on the demand side, allowing for molecules to be exported or imported, allowing for these new markets such as maritime fuels to be served,” he said. “It’s really a connector and an ‘un-locker’ of this infrastructure that will allow these new hubs of energy to be developed. We believe that these are very critical infrastructure. This asset class will really serve as the gateway of energy of the future. The whole point is for these assets to allow us to get to the 2050 net-zero goals. It’s really to serve the next 20, 30 years of large volumes of clean energy across the world.”

Meticulous Planning is Key

But getting to that point will require a lot of planning while working with existing asset and port owners and cities that may already have a plan, according to Metelo.

“What they need is to develop a business to bring in investors and develop a business plan,” he said. “In those cases, we’ll try to develop with them, together with the demand side and potential tenants, a business plan that can be financeable, and then crowd-in private capital to support those. In other cases, it can be really sitting down with them and identifying all the opportunities of development in these assets.”

Metelo brings up an example of everyone wanting a hydrogen electrolyzer, which can be used to create hydrogen using renewable energy as a power source.

Massive projects like the ones implemented for wind energy take time to develop and turn into reality. (Courtesy: Gateway Zero)

“However, that may not be the need; that may not be what fits that market,” he said.

“It’s really sitting down with existing cities and authorities and understanding what the needs are of the market and how we can develop a local strategy and a business plan that can be financed by private capital. It can vary quite a bit, but the common theme is that we definitely always sit down with port asset owners and port operators that are already active in the business.”

Meeting the Needs

Massive projects like the ones implemented for wind energy take time to develop and turn into reality, so constant planning and vigilance are a necessity from start to finish, according to Metelo.

“The reality is for most energy projects, when they need a port, it’s already too late,” he said. “It’s already when they need an infrastructure like this. I really see over the next 10 years, 15 years, is a largely interconnected global industry where the word ‘renewables’ will probably disappear. Renewables equals energy. Energy equals renewables.”

And just as the oil and gas sector has done for the last 150 years, Metelo said renewables is moving toward that worldwide interconnectedness, whether that means by transmission, electrons, or liquid forms over land, sea, or air. These interconnecting points will link supply and demand and push for a deployment that will move, store, and process energy.

“We’re going to be developing new energies that will be coming from different places and going to different places,” he said. “That’s where I believe a major re-imagining of these infrastructures will be required. We expect Gateway Zero to be right in the middle of that interconnected world and where we’ll hopefully be a leading investor and asset owner in this space where we can really develop these energy gateways of the future on a global scale.” 

More info www.gatewayzero.com

Test and Repair 250 feet in the Air

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Over the years, the use of wind power has created a great deal of well-paying jobs, including everything from technicians, researchers, and designers to workers on new wind-energy farms and those that create the latest wind-energy gadgets and discover the latest technology to make wind power even better. Currently, there are more than 125,000 people working in the wind industry across the United States, and that number continues to grow. According to the U.S. Bureau of Labor Statistics, wind-turbine service technicians are the fastest growing U.S. job of the decade, and with good reason.

Each year in the United States, 380 billion kW/h are generated by wind turbines that convert kinetic energy from the wind into electrical power. But what happens when these $2-million to $4-million wind turbines that stand 280 feet in the air with blades ranging in length from 40 feet to 250 feet, experience some sort of mechanical malfunction? What happens if a blade becomes damaged due to a bird strike, lightning strike, blade detachment, leading-edge erosion, or blade crack? Skilled technicians are needed to correct the problem.

Wind technicians, who evaluate the turbine and its blades and get the turbine back up and running, are a vital part of the process that helps to generate wind power. (Courtesy: Shutterstock

These technicians, who evaluate the turbine and its blades and get the turbine back up and running, are a vital part of the process that helps to generate wind power.

Rope Partner, in Centennial, Colorado, is a provider of at-height maintenance, inspection, and performance enhancements for wind-turbine operations that require specialized access approaches. For more than two decades, the company’s WindCorps® technicians have completed several thousand projects for every major manufacturer of wind turbine, as well as for the majority of wind-farm owners across the United States. They are experts in testing these massive structures when there is a malfunction or complete failure.

Figure 1: A wind turbine on a wind farm. (Courtesy: Megger)

Trouble with the Lighting Protection System

Recently, a client of Rope Partner’s was having an issue with its wind-turbine blade lightning protection system (LPS). This system is particularly important to a turbine because it prevents physical damage to the structure by redirecting a lightning strike from the blade to ground. If lightning strikes an unprotected blade, an explosive expansion of the air within the blade can occur, resulting in severe damage to the blade surface and downtime of the turbine. Because this system is so crucial to protecting the wind turbine, Rope Partner was asked to examine, test, and diagnose what was going on with the LPS and how it could be remedied.

Testing wind turbines can be very tricky if you don’t have the right test equipment, as they reach extremely high elevations, and their movement through the air causes ionization, which creates a target for cloud charge that can develop in the atmosphere, making the blades susceptible to lightning strikes. The only protection the blades have against these strikes is a properly working LPS.

Examine, Test and Diagnose

To figure out what the exact problem was with the LPS and why it wasn’t working properly, technicians needed to test the system while it was installed on the turbine.

The most common way to start the assessment is to test from the root of the blade to each receptor on the blade. If this test fails, then technicians try to diagnose the connectivity issue by using different test points on the blade. This not only requires a technician to test between receptors on the blade, but it also requires the technician to bring various pieces of equipment out on the blade. This is not an easy task when hauling big, bulky equipment such as an ohmmeter, voltage tester, multimeter, oscilloscopes, infrared testers, and fiber optic equipment while climbing a wind-turbine tower and going out on a rope to perform an inspection and repair.

For the technician to pick up these potential faults, what is needed is a higher test current of 1A or more. This is because blades can be up to 100 meters long and are tested tip to hub. Test leads that can reach that length must be designed with low enough resistance to not overwhelm the instrument’s capabilities and invalidate the test. Most instruments cannot be used to perform this task.

For years, Rope Partner used a Digital Low Resistance Ohmmeter (DLRO) that measured low resistance values in micro-ohms at specified currents. However, the unit they were using encountered frequent issues with setup, causing incorrect readings.

This was a problem for our techs whose primary scope is blade repair,” said Lucas Llado, vice president, business development, Rope Partner. “It is extremely important for techs to have a device that is foolproof to set up, as LPS testing is not a scope of work that is performed frequently — maybe just once or twice a month. Since LPS testing isn’t performed often, it is important to have a device that is easy to use and completes the task accurately. It is also essential to have a reliable device when an open circuit is found.”

Figure 2: Technician out on a rope using DLRO on a blade. (Courtesy: Megger

A Better Testing Tool

With technicians getting frustrated, and results not being what they should be, Rope Partner decided to look for a new tester. With industry references and doing some research on its own, the company learned about the DLRO2 from Megger.

“This unit is easy for a single technician to handle while out on the rope during inspection,” Llado said. “Previous models we used were big and bulky and required more than one person in the air.”

Given the small footprint of the DLRO2 and the ability to use long test leads with it, all LPS testing can be performed quicker and easier with one tool.

The compact, handheld design of these 2A low resistance ohmmeters provides relative high output, accuracy, and repeatability. They fit easily in a toolbox and be used in tight and hard-to-reach spaces.

When a technician has limited space while hanging from a rope, having a tester that has a small footprint and is lightweight greatly improves workflow.

“Being able to just plug the leads in with banana connectors helps to make setup easier and more efficient,” Llado said.

“This unit also makes attaching leads with banana connectors much easier than trying to attach with lugs that often come loose when leads are moved.”

The unit can also display the results of the last three readings, take timely photos, and has the ability to take one photo to be included with the report.

“By using the DLRO, we were able to detect the non-conductivity and realized that the LPS was damaged,” Llado said. “Once this was identified, we were able to repair it quickly.”

LPS systems are tested in accordance with the IEC 61400-24 standard. By partnering with these clients and using the correct tools, while applying safe, cost-effective, and environmentally appropriate solutions, Rope Partner has been successful in reducing turbine downtime, increasing production-based availability as well as the lifespan of its clients’ turbines. 

3D printing vs. CNC machining for component manufacturing

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In the face of rising pressure to meet sustainability goals, manufacturers are urgently seeking the most energy efficient ways to produce parts for demanding applications without compromising on strength or performance. Exploring the pros and cons of CNC machining versus 3D printing can help manufacturers select the right technology.

What is particularly alluring about 3D printing’s multiple benefits is its customization capabilities, a strong selling point for the technology in the wind sector. (Courtesy: Get It Made)

NetZero Now or Never

The industrial sector is responsible for 24 percent of emissions in the U.S., according to the US Environmental Protection Agency (EPA), a figure that doesn’t even factor in the huge environmental impact of shipping parts across the globe. In the renewables sector, the race to NetZero combined with increasing demand for wind energy is placing growing pressure on companies to seek out more efficient processes and materials for manufacturing wind-turbine parts and components. 

Harnessing renewable energy itself doesn’t come without its own challenges, but there is also the manufacturing of renewable energy components, which often requires complex processes and high precision. Added to this are extreme environmental conditions, rigorous industry regulations, keeping operational costs low, as well as powering society continuously — all elements that must be carefully considered when manufacturing parts for energy-industry applications.

The Game-Changing Benefits of 3D Printing

It is becoming clear that additive manufacturing (AM), or 3D printing, has merely scratched the surface of its potential and is poised to be a game changer for the future of the energy generation industry. It has the potential to bring a step-change in cost and performance competitiveness in the wind industry, while contributing to decarbonization efforts.

Major trends in supply chain and sustainability are driving demand for a global market estimated to reach more than $50 billion by 2025, as a growing number of manufacturers are embracing the benefits of this rapidly emerging technology.

Its rise presents a compelling proposition to the energy sector, ensuring fast turnaround times and enabling customization through design flexibility while improving energy efficiency and eliminating expensive tooling costs. Moreover, it allows for cost-effective rapid prototyping, speeding up the development of new energy technologies. As a result, manufacturers are employing online 3D printing to accelerate the deployment of new renewable energy sources.

As AM or 3D printing does not require a tool or mold, producers may create more efficient, high-strength, lightweight structures where traditional manufacturing procedures fail. This is especially essential considering that raw material costs are rising around the world, making material consumption reduction an increasingly vital factor in product development and manufacturing. For most components, excess material from conventional manufacturing may be removed during the design stage, making 3D printing more cost effective over the whole lifecycle of the part.

What is particularly alluring about 3D printing’s multiple benefits is its customization capabilities, something which is a strong selling point for the technology in the wind sector. It means more efficient designs can be customized to specific locations and applications; for instance, while the standard design for a wind turbine at a given location may call for towers to be 90 meters tall, more precise evaluations onsite may reveal that towers of 120 meters tall are a more logical solution in one specific section. What this also translates to is the possibility of 3D printing 30-meter tower components onsite to add to the existing, standard 90-meter base in order to achieve optimal performance. This strategy is more sustainable than traditional practices for two reasons: Firstly, it would increase the overall quantity of clean, renewable energy that may be generated, and, secondly, it would reduce the carbon footprint by lowering the number of components that need to be produced and transported for many miles.

As AM or 3D printing does not require a tool or mold, producers may create more efficient, high-strength, lightweight structures where traditional manufacturing procedures fail. (Courtesy: Get It Made)

Key IP Challenges

However, there are a few areas where the technology currently falls short: Increasing public focus on the energy industry, pandemic-related volatility, and recent events in Ukraine are all contributing to market disruption. During difficult times, businesses frequently turn to their intellectual property to safeguard their position in existing markets and create new opportunities. Because additive manufacturing is playing an increasingly essential role in facilitating these transformations, it is critical that IP strategies and portfolios be appropriate for the 3D-printing environment.

Perhaps the most serious intellectual property danger confronting the energy business as additive manufacturing grows is how to regulate the spread of digital files needed to additively manufacture products. To address this risk, organizations must establish patents and other intellectual property rights with an understanding of how to protect each phase in the additive manufacturing value chain.

AM Innovation: GE’s Haliade-X Offshore Turbine

One use case demonstrating the renewable energy transition with 3D printing is General Electric’s joint project to develop the world’s largest 3D printer for offshore wind applications. The technology is aimed to speed up and optimize the production of casting components of GE’s Haliade-X offshore turbine.

In 2021, the U.S. Department of Energy (DoE) granted GE a $6.7 million project to investigate the design and manufacturing of 3D printed wind-turbine blades. Working with Oak Ridge National Laboratory (ORNL) and the National Renewable Energy Laboratory (NREL), GE sought to boost the competitiveness of onshore and offshore wind energy by leveraging 3D printing to lower production costs and improve supply chain flexibility. The turbine blade tips that were fabricated using 3D printing and thermoplastic composites have various advantages, including being lighter than traditional counterparts. Lightweighting permits larger turbine rotors to create more power while also decreasing pressure on the turbine’s gearboxes, drivetrains, bearings, and foundation, as well as lowering turbine operators’ lifetime expenses.

Not only that, but when 3D-printed thermoplastic blade tips approach the end of their useful life, they may be melted down and recycled, which is an important feature of GE Renewable Energy’s initiative. The team is also looking into how other elements of the turbine blade might benefit from 3D printing technologies and thermoplastic materials to improve component time-to-market, quality, and sustainability. Through its adoption of 3D printing, GE is aiming to not only improve cost and performance competitiveness in the wind industry, but sees it accelerating the energy transition even more rapidly.

The Gains in CNC Machining

CNC machining plays a crucial role in overcoming the challenges found in manufacturing, allowing for high-precision manufacturing of components, which is key to improving the efficiency and functionality of wind-energy systems. Additionally, CNC machining offers other advantages by helping reduce costs and waste in the production process, making renewable energy solutions more affordable and accessible.

A prototype of a wind-turbine base 3D printed from concrete. (Courtesy: GE)

Wind-turbine blades, often comprised of composite materials, must be manufactured with great precision to ensure optimal performance. These blades can be precisely carved and shaped using CNC machining, allowing them to catch wind energy more efficiently and to withstand wind pressure without disintegration; specialist metals and carbon fiber are crucial for ensuring the blades remain lightweight. Furthermore, CNC machining can be used to manufacture other wind-turbine components such as gearbox housings and generator frames. In fact, the majority of the critical driving components and blades found inside the turbine’s nacelle housing are among the most common wind-turbine parts manufactured with CNC machining. Other driving components include gears, rotors, main shafts, braking components, hubs, and YAW system components.

Aside from generating driving components, CNC machining makes it easier to manufacture the massive pitch bearings necessary for the wind turbine’s blade angle adjustment mechanism.

Additionally, the use of CNC machining in wind-energy production can assist in waste reduction as more precise cutting means less material use. This not only assists in lowering costs but also helps to ensure the long-term viability of wind-energy generation.

Harsh environment applications call for robustness and durability, another reason why CNC machining is the manufacturing method of choice as it can produce long-lasting parts that are critical to endure enormous stress and the wear of consistent use while maintaining dimensional stability.

Design and Cost Challenges

While CNC machining provides greater dimensional accuracy than 3D printing, the quickly evolving innovation being seen in additive manufacturing means that perhaps it is only a matter of time before this changes and 3D printing technology matches, or even surpasses, CNC machining’s precision in this respect. And while CNC machining produces products with superior mechanical characteristics in all three dimensions, this makes the method frequently more expensive, particularly for smaller batches of items.

Wind turbines on the beautiful autumn meadow.

There are also a few other potential barriers to CNC machining adoption in the energy business. Certain design challenges related with CNC operations come into play; without additional tools, CNC machines struggle to produce parts with inner corners, hollow features, and undercuts. When making parts for the energy industry using these design elements, the machine would need to do additional setups, secondary operations, or tool changes, which would affect production costs and time.

The Future Landscape

Moving forward, the renewable energy sector is only going to increase and expand. As renewable energy manufacturers continue to look for ways to increase product capabilities and performance while simultaneously meeting ambitious goals for efficiency and sustainability, 3D printing offers an ideal solution. However, it is crucial not to overlook the benefits of CNC machining before making the right choice. 

Why it’s time to reboot renewable energy due diligence

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The success of any big investment, whether you are buying a house or acquiring a wind farm, hinges on thorough due diligence (DD). Nobody dives into a purchase without a solid understanding of what they’re getting themselves into.

Renewables DD requires an intricate interplay between the asset owner, their lenders and investors, and the specialist legal, technical, insurance and financial advisers engaged to assess project risks.

These expert advisers play a pivotal role in giving capital providers the confidence to back vital wind, solar, and storage projects, boasting impressive long-term track records in the sector.

The surge in demand for renewable energy, driven by a global commitment to sustainability, has fostered significant growth in the sector. (Courtesy: Shutterstock)

However, the efficiency with which they can impart their hard-won knowledge is hampered by traditional approaches in the DD process, which tend to be time-consuming, resource intensive, and ultimately place an unnecessary burden on their clients.

DD doesn’t need to be this hard — and, as pressure grows to accelerate capacity growth worldwide, it’s clear that now is the time for a “reboot.”

Market forces drive advisers to focus on streamlining due diligence

The surge in demand for renewable energy, driven by a global commitment to sustainability, has fostered significant growth in the sector. As nations and industries transition toward cleaner energy sources, investors are confronted with an expanding array of opportunities.

In the U.S. market, the Inflation Reduction Act (IRA) is driving significant interest, resulting in investor appetite far exceeding the availability of high-quality projects. In the U.S., as is the case globally, there is a pressing need to expedite the capital flow into new projects. This acceleration is crucial to ensure projects move through the pipeline as quickly as possible, ultimately enabling developers to reinvest elsewhere and bring more capacity online.

With increased competition in the market, fueled by the growing attractiveness of sustainable investments, the race to secure high-quality projects has intensified. As ESG considerations intertwine with investment decisions, companies find themselves not only competing for projects based on financial metrics but also on their ability to meet ESG standards, bringing additional intricacies.

Additionally, rapid technological advancements, such as innovations in floating wind, energy storage and green hydrogen, coupled with new financing and offtake structures, demand a DD process that is not only efficient but also capable of keeping pace with the latest industry innovations.

In the dynamic landscape of DD, advisers must focus on putting into operation their unique institutional knowledge to provide swift insights derived from specialist industry expertise. Simultaneously, the demand for faster and earlier insights underscores the importance of effective, more transparent collaboration with clients’ full advisory teams to navigate complex deals and shorter transaction timeframes.

Tackling due diligence bottlenecks

So, how can this be achieved in practice?

Streamlining due diligence will require a concerted effort to identify and address a number of key bottlenecks — but the simple solution lies in bringing together disparate forms of transaction communication and reporting into one place.

Streamlining due diligence will require a concerted effort to identify and address a number of key bottlenecks — but the simple solution lies in bringing together disparate forms of transaction communication and reporting into one place. (Courtesy: LiveDiligence)

Adoption of modernized reporting practices: Lengthy and intricate reports, often 300-plus pages long, can be replaced with digital tools that allow advisers to provide more timely, manageable updates.

Enhancing communication through collaborative platforms: Real-time communication is needed to foster more seamless inter-adviser cooperation. Utilizing a single platform that brings all advisers under one roof streamlines operations and reduces administrative burdens. By automatically collating systems, this eliminates unwieldy Q&As and reduces the risk of missing critical points.

  • Deal visibility: Establishing a centralized platform for monitoring progress and timelines ensures a coordinated workflow. This enables teams to track risks, status and Q&A, and maintain an organized and informed approach throughout the due diligence process.
  • Centralizing information: Consolidating all project-critical information into one platform addresses the challenge of fragmented or siloed data, providing a unified, source of truth accessible to involved parties.
  • Integration of advanced tools: Incorporating tools serves to streamline routine tasks, enhancing efficiency and accuracy. Gone are the days of lengthy documents compiled from various inputs and disconnected information.

Gaining a competitive edge through better knowledge management

Due-diligence advisers have been grappling for some time with how to use technology to improve their services and move away from outdated and burdensome approaches to DD. While advisers possess significant expertise in assessing the feasibility and risk of projects, there is a significant opportunity for them to enhance their practice by embracing digital solutions. This will ensure that their hard-won knowledge and experience is readily accessible throughout their organizations, contributing to more streamlined and efficient processes and enhanced client offering.

Rapid technological advancements, such as innovations in floating wind, energy storage and green hydrogen, coupled with new financing and offtake structures, demand a DD process that is not only efficient but also capable of keeping pace with the latest industry innovations. (Courtesy: Shutterstock)

A number of frontrunners are emerging in the race by advisers to put into operation their institutional knowledge. Global law firm DLA Piper and global technical consultancy Wood, are taking a leading role in the “reboot” of due diligence, having recently agreed to long-term deals with LiveDiligence to improve the transaction experience for their clients.

This ensures valuable expertise is not only retained within their organizations but actively put to use in decision-making. There is a pressing need to speed up processes to reduce the lag between renewable-energy project conception and the deployment of investor and lender capital. It’s important to realize this goal can be achieved without compromising the quality of service and insight provided.

A centralized, digitalized DD approach offers the advantage of delivering faster and earlier insights, ultimately reducing the time it takes to reach financial close. In a sector where timely decision making is paramount to speeding up transaction timelines, streamlining due diligence emerges as a strategic necessity to navigate the changing requirements of the modern clean-energy landscape. 

US Forged Rings to invest $700M in tower facility

US Forged Rings Inc. has announced a $700 million investment in the U.S. offshore wind industry to construct a tower fabrication facility and a steel forging plant. The U.S.-based company will use the two facilities to service the growing domestic offshore wind market, filling a supply chain gap for offshore wind components and alleviating bottlenecks for a market with goals of deploying 30 GW by 2030 and 110 GW by 2050.

Through its strategic supply chain partnerships with Nucor, North America’s largest steel producer and recycler, providing sustainable steel for offshore wind-tower construction, and Ellwood Quality Steels, North America’s leading ingot caster, USFR is committed to producing final products that are 100 percent made in the U.S.

US Forged Rings is investing $700 million in the U.S. offshore wind industry to construct a state-of-the-art tower fabrication facility and a steel forging plant. (Courtesy: US Forged Rings)

The tower fabrication facility will produce 100 fully coated towers annually that include internally produced flanges, eliminating potential delays and logistics issues, lowering the overall cost.

The facility is designed from its inception to be expandable up to 200 towers annually, depending on demand. The new steel forging facility will produce large flanges up to 40 feet in diameter, making it the largest ring rolling facility in North America and Europe.

The facility will also produce forged components required in other heavy industries including nuclear energy, construction, shipping, and mining.

“This substantial investment serving U.S. offshore wind was spurred by our confidence in the medium and long-term prospects of the U.S. market, which is in its early phases of development and needs a local supply chain to rely on,” said Giacomo Sozzi, president of USFR. “These facilities will enable U.S. developers and OEMs to have predictable costs and a reliable supply of vital components. Equally important, the investment will result in direct environmental benefits including the reduction of significant pollution emitted by otherwise shipping these huge components from overseas.”

Once all permits and regulatory approvals are secured, construction of the facilities is expected to take 16-20 months, with first towers beginning production in Q1 2026. The two facilities will create more than 500 U.S. full-time employment positions. The facilities will also limit carbon footprint by using 77 percent recycled content, making it a fraction of the global average. 

“We are currently in the final stages of evaluating several potential locations on the East Coast,” said Slavko Zurovac, USFR’s managing director. “All potential sites are strategically positioned with access to required waterways, rail, and utilities, providing significant logistical benefits and making it competitive to supply large components.” 

More info www.usfr.com

Nearthlab, PowerCurve team to streamline O&M

Nearthlab, a leading provider of autonomous drone solutions, and PowerCurve, a pioneer in annual energy production (AEP) loss analysis, recently signed a memorandum of understanding (MoU) aimed at optimizing wind-farm operations and maintenance (O&M).

Nearthlab has been redefining drone solutions since 2015, pushing practical boundaries beyond industry norms. (Courtesy: Nearthlab)

Under the agreement, Nearthlab’s cloud-based analytics platform, Zoomable, will integrate aerodynamic performance calculation capabilities from PowerCurve’s flagship AEP analysis tool, AeroVista, into its framework. The integration will enable site managers to understand AEP loss attributed to each blade surface defect, such as leading-edge erosion identified through Zoomable.

Surface degradation on the leading edge often leads to significant power output reductions. With AeroVista integrated into Zoomable, site managers will be able to determine the impact of each defect on turbine performance, facilitating targeted maintenance and resource allocation.

“Spotting defects is one thing; understanding their financial impact is another,” said Jay Choi, co-founder and CEO of Nearthlab. “Teaming up with PowerCurve marks a significant step towards fostering an environment where wind farms can operate at their best.”

Niels Bruhn Brønnum, CEO of PowerCurve, echoed Choi’s sentiments.

“Driven by the shared commitment to a sustainable future, our partnership will redefine how the wind industry approaches O&M,” he said.

More info www.nearthlab.com | www.powercurve.dk